Integrated model for thermo-mechanical controlled process in rod (or bar) rolling

This study presents an integrated model for computing the thermo-mechanical parameters (cross-sectional shape of workpiece, the pass-by-pass strain and strain rate and the temperature variation during rolling and cooling between inter-stands) and metallurgical parameters (recrystallisation behaviour and austenite grain size—AGS), to assess the potential for developing “Thermo-Mechanical Controlled Process” technology in rod (or bar) rolling, which has been a well-known technical terminology in strip (or plate) rolling since 1970s. The advantage of this model is that metallurgical and mechanical parameters are obtained simultaneously in a short computation time compared with other models. The model has been applied to a rod mill to predict the exit cross-sectional shape, area and AGS per pass by incorporating the equations for AGS evolution being used in strip rolling. At the finishing train of rod mills, the strain rates reach as high as 1000–3000 s−1 and the inter-pass times are around 10–60 ms. The results show that the proposed model is an efficient tool for evaluating the effects of process-related parameters on product quality and dimensional tolerance of the products in rod (or bar) rolling. The results of the simulation demonstrated that the equation for AGS evolution being used in strip rolling might have limitations when applied directly to rod rolling at a high strain rate